End-of-line (EOL) packaging machinery is built to last. When thoughtfully specified and engineered by a reputable OEM, it should provide reliable performance for years.
But when equipment isn’t designed for the environment where it’s used, that careful ROI justification behind the six-figure capital expense becomes meaningless.
The most frequent concerns about operating environment for EOL packaging machinery come out of the food and beverage markets, where equipment may be used in areas subject to regular washdown and/or sanitizing protocols, according to Chris Rempe, product manager at Combi Packaging Systems.
In fact, that’s the story behind a recent order placed with Combi by just such a business. Here’s what happened:
In 2020, with the COVID-19 pandemic taking hold, a company in the beverage industry had a pressing need to increase throughput of its EOL packaging operation. Faced with global supply chain backups and parts shortages for specialized machinery, the company couldn’t wait for delivery of a system built to withstand daily washdown procedures. Instead, it opted for a conventional drop-packing line from a reputable manufacturer that could promise a short lead time for delivery.
Four years later, the machine panels were corroding, parts were failing prematurely, downtime and maintenance costs were climbing and the company was shopping again for a new EOL packaging line.
This time it selected a drop-packing system from Combi specifically designed to withstand daily water and chemical washdowns.
When installed, the new system will include a case erector, drop-packer and carton sealer – all built with corrosion-resistant stainless steel, protected motors and components and designed to work as a single system rather than a chain of standalone machines.
Food packaging represents about 40 percent of Combi’s business, Rempe says, and he’s unaware of any other equipment manufacturer that has such a variety of solutions specifically engineered to the needs of food processors and packagers. “A number of manufacturers offer upgrades like stainless panels to help protect against premature wear in washdown or sanitary environments,” Rempe says. “But our equipment is designed from the ground up to operate in the specified environment, so you get superior performance and protection.”
Combi machinery is available in three design levels, with materials and features optimized for specific conditions, ensuring compliance with food safety standards, extending equipment life span and maximizing performance.
Wipe Down Design: This is the standard design of Combi equipment, built for hard use in areas that aren’t exposed to water spray and washdown procedures. It’s compatible with light manual cleaning and can be customized with relevant options such as catch trays to contain product spillage that could damage the machine.
Washdown Design: This design level is built to withstand daily washdowns with sanitizing chemicals. It can handle low-pressure rinsing but is not intended for high-pressure or high-temperature cleaning.
Sanitary/RTE Washdown Design: This level is for use in areas where ready-to-eat (RTE) food processing takes place. It meets the same standards as the washdown design but is also engineered to minimize crevices where pathogens can hide and colonize, based on the design principles detailed in the Meat Foundation publication Food Safety Equipment Design Principles: Checklist and Glossary. (See “10 design principles” below.)
For a side-by-side comparison of the three design levels, click here.
The upgraded designs come at a price. Depending on the features and complexity, a washdown system might cost up to 50 percent more than a similar machine at the standard wipe-down level. A sanitary/RTE system might cost twice as much as the comparable wipe-down system.
“It’s designed to be easy to clean. You may pay considerably more for the machine, but it’s a cheap insurance policy against injuring people, or worse,” Rempe says. “There’s no reason to incur the cost of a washdown or sanitary design if you don’t need it. But if you do, there aren’t very many options out there.”
Across the food industry, most EOL operations are segregated from food processing operations to minimize contamination risk. About 80 percent of Combi equipment installations are for its standard wipe-down design level.
Perhaps surprisingly, most of the rest – about 15 percent of the total – are the sanitary/RTE design level.
“The washdown design is for when you’re concerned about the equipment holding up to the operating environment. The end-users who need the sanitary/RTE design are addressing the bigger concern of pathogens and bacteria,” Rempe says.
These are typically operations that have limited space, perhaps in legacy facilities, and have no choice but to conduct EOL packaging in areas alongside food processing and primary packaging activities.
“We have a number of existing end-users that have been using our sanitary designs for years and they repeat buy them as they replace older equipment or expand their production,” Rempe says.
10 design principles for equipment used in sanitary/RTE environments
While the Meat Institute guidelines go into further detail, here are the major principles, which Combi follows in machinery for the sanitary/RTE environment:
- Made of materials compatible with the product, environment, chemicals and sanitation methods.
- Easy accessibility for inspection, maintenance and sanitation.
- Self-draining to prevent accumulation of materials that promote bacteria growth.
- Hollow areas are hermetically sealed.
- Free of niches, recesses, open seams, gaps, etc., where pathogens can hide.
- Normal equipment operation doesn’t contribute to unsanitary conditions (such as control panels located above product zones, etc.).
- Maintenance enclosures and controls are designed to prevent product residue or water penetration/accumulation.
- Subsystems, such as exhaust and drainage, don’t contribute to food safety risk.
- Cleanable to a microbiological level.
- Cleaning and sanitizing procedures are clearly written, designed and proven effective.
If your operations require machinery that can handle a tough environment, contact Combi Packaging Systems to see how we can meet your needs.